Heater, Air Conditioner and Ventilation

55-1
HEATER,
AIR CONDITIONER
AND VENTILATION
CONTENTS
55109000164
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 8
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . 3
Sight Glass Refrigerant Level Test . . . . . . . . . . 8
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 4
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 5
Magnetic Clutch Test . . . . . . . . . . . . . . . . . . . . . . 8

Receiver Drier Test . . . . . . . . . . . . . . . . . . . . . . . . 8
Compressor Drive Belt Adjustment . . . . . . . . . . . 8
Dual Pressure Switch Check . . . . . . . . . . . . . . . 9
CONTINUED ON NEXT PAGE
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related
component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors and
interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or
maintenance) are indicated in the table of contents by an asterisk (*).
55-2
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Performance Test . . . . . . . . . . . . . . . . . . . . . . . . 14
Refrigerant Leak Repair . . . . . . . . . . . . . . . . . . . 16
Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Relay Check . . . . . . . . . . . . . . . . . . . . . . 17
Idle-up Operation Check . . . . . . . . . . . . . . . . . . 18
Air Purifier Assembly Replacement . . . . . . . . . 18
HEATER CONTROL ASSEMBLY AND A/C

SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AIR THERMO SENSOR . . . . . . . . . . . . . . . . 25

BLOWER MOTOR ASSEMBLY, AUTOMATIC
COMPRESSOR-ECU AND INSIDE/OUTSIDE
AIR CHANGEOVER DAMPER MOTOR . 26
COMPRESSOR AND TENSION
PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CONDENSER AND CONDENSER FAN
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REFRIGERANT LINE . . . . . . . . . . . . . . . . . . 33
HEATER UNIT*, BLOWER UNIT*,

RESISTER* AND EVAPORATOR* . . . . . . . 22
VENTILATORS* . . . . . . . . . . . . . . . . . . . . . . . . 36
HEATER, AIR CONDITIONER AND VENTILATION - General Information
GENERAL INFORMATION
The heater system uses a two-way-flow full-air-mix
system that features high performance and low
operating noise, and includes an independent face
air blowing function. The A/C system is basically
the same as the conventional system, but a new
Items
Heater unit
55-3
55200010312
refrigerant system has been adopted as a response

to restrictions on the use of chlorofluorocarbons.
In addition, an air purifier which carries out fine
A/C control has been included.
Specifications
Type
Two-way-flow full-air-mix system
Heater control assembly
Dial type
Compressor
Model
Scroll type <CSC08>
Dual pressure switch

kPa
High-pressure switch
ON OFF: 2,940, OFF ON: 2,350
Low-pressure switch
ON OFF: 196, OFF ON: 221
Refrigerant and quantity g
SAFETY PRECAUTIONS
Because R-134a refrigerant is a hydrofluorocarbon
(HFC) which contains hydrogen atoms in place of
chlorine atoms, it will not cause damage to the
ozone layer.
Refrigerant R-134a is transparent and colourless
in both the liquid and vapour state. Since it has
a boiling point of - 29.8_C, at atmospheric pressure,
it will be a vapour at all normal temperatures and
pressures. The vapour is heavier than air,
non-flammable, and nonexplosive. The following
precautions must be observed when handling
R-134a.
Caution
Wear safety goggles when servicing the
refrigeration system.
R-134a evaporates so rapidly at normal
atmospheric pressures and temperatures that it
tends to freeze anything it contacts. For this reason,
extreme care must be taken to prevent any liquid
refrigerant from contacting the skin and especially
the eyes. Always wear safety goggles when
servicing the refrigeration part of the A/C system.
Keep a bottle of sterile mineral oil handy when
working on the refrigeration system. Should any
liquid refrigerant get into the eyes, use a few drops
of mineral oil to wash them out. R-134a is rapidly
absorbed by the oil. Next splash the eyes with
plenty of cold water. Call your doctor immediately
even though irritation has ceased after treatment.
Caution
Do not heat R-134a above 40_C
R-134a (HFC-134a), Approx. 500 - 600
In most instances, moderate heat is required to

bring the pressure of the refrigerant in its container
above the pressure of the system when charging
or adding refrigerant.
A bucket or large pan of hot water not over 40_C
is all the heat required for this purpose. Do not
heat the refrigerant container with a blow torch
or any other means that would raise temperature
and pressure above this temperature. Do not weld
or steam clean on or near the system components
or refrigerant lines.
Caution
Keep R-134a containers upright when charging
the system.
When metering R-134a into the refrigeration system
keep the supply tank or cans in an upright position.
If the refrigerant container is on its side or upside
down, liquid refrigerant will enter the system and
damage the compressor.
Caution
1. The leak detector for R-134a should be used
to check for refrigerant gas leaks.
2. Do not allow liquid refrigerant to touch bright
metal.
Refrigerant will tarnish bright metal and chrome
surfaces, and in combination with moisture can
severely corrode all metal surfaces.
55-4
HEATER, AIR CONDITIONER AND VENTILATION
Service Specifications/Lubricants/Special Tools
SERVICE SPECIFICATIONS
55200030332
Items
Standard value
Idle speed r/min
650 50
Idle up speed r/min
800 50
Resistor (for blower motor) W
LO: 2.30, ML:1.10, MH: 0.40
Air gap (Magnetic clutch)
0.25 - 0.55
LUBRICANTS
55200040236
Items
Specified lubricants
Quantity
Each connection of refrigerant line
DENSO OIL 8
As required
Compressor refrigerant unit lubricant mL
DENSO OIL 8
60 - 100
SPECIAL TOOLS
Tool
55200060157
Number
Name
Use
MB991367
Special spanner
Removal and installation of armature mounting

nut of compressor
MB991386
Pin
55-5
HEATER, AIR CONDITIONER AND VENTILATION - Troubleshooting
TROUBLESHOOTING
55200070389
TROUBLESHOOTING PROCEDURES
Trouble symptom
Problem cause
Remedy
Reference
page
When the ignition

switch is ON,
the A/C does not
operate
Fuse is defective
Replace the fuse
Harness or connector is defective
Repair the harness or connector
A/C compressor relay is defective
Replace the A/C compressor

relay
55-17
A/C compressor magnetic clutch is defective
Replace the armature plate, rotor

or clutch coil
55-8
Refrigerant leak or overfilling of refrigerant
Replenish the refrigerant, repair

the leak or take out some of the
refrigerant
55-8
Dual pressure switch is defective
Replace the dual pressure switch
55-9
A/C switch is defective
Replace the blower switch assembly
55-20
Blower switch is defective
55-20
Automatic compressor-ECU is defective
Replace the automatic compressor-ECU
55-7
Engine-ECU is defective
Replace the engine-ECU
When the A/C is

operating, temperature inside
the
passenger
compartment
doesnt decrease
(cool air is not
emitted)
Refrigerant leak
Replenish the refrigerant and

repair the leak
55-8
Dual pressure switch is defective
Replace the dual pressure switch
55-9
Automatic compressor-ECU is defective
Replace the automatic compressor-ECU
55-7
Blower fan and

motor do not turn
Fuse is defective
Replace the fuse
Blower relay is defective
Replace the blower relay
55-17
Blower fan and motor are defective
Replace the blower fan and

motor
55-26
Resistor (for blower motor) is defective
Replace the resistor
55-24
55-20
55-6
Trouble symptom
Problem cause
Remedy
Reference
page
Blower fan and

motor do not stop
turning
55-20
Blower relay is defective
Replace the blower relay
55-17
Fuse is defective
Replace the fuse
Condenser fan motor is defective
Replace the condenser fan motor
55-32
Radiator fan motor is defective
Replace the radiator fan motor
Inside and outside changeover switch is

defective
55-20
Inside and outside changeover damper motor

is defective
Replace the inside and outside

changeover damper motor
55-26
When the A/C is

operating condenser fan or radiator fan does
not turn
Inside and outside changeover

does not operate
INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL
55-7
55201030096
Terminal
No.
Check item
Checking requirements
Normal condition
Earth
Always
0V
Input from air thermo sensor to

Automatic compressor-ECU
Air thermo sensor detection temperature: 5_C
1.1 V
Automatic compressor-ECU power

supply (IG2)
Ignition switch: ON
Battery voltage
Output from ECU to A/C compressor

relay
A/C compressor relay: OFF
Battery voltage
A/C compressor relay: ON
0V
Air thermo sensor earth
Always
0V
7- 10
11
Input from A/C switch to Automatic

compressor-ECU
A/C switch: OFF
0V
A/C switch: ON
Battery voltage
Output from ECU to engine-ECU
Air thermo sensor detection temperature: 5_C or less
Battery voltage
Air thermo sensor detection temperature: 8_C or more
0V
12
55-8
HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service

Sight glass
ON-VEHICLE SERVICE
55200840225
SIGHT GLASS REFRIGERANT LEVEL TEST

The sight glass is a refrigerant level indicator. To check the
refrigerant level, clean the sight glass and start the vehicle
engine. Push the A/C button to operate the compressor, place
the blower switch to high and move the temperature control
lever to max cool. After operating for a few minutes in this
manner, check the sight glass.
1. If the sight glass is clear, the magnetic clutch is engaged,
the compressor discharge line is warm and the compressor
inlet line is cool; the system has a full charge.
2. If the sight glass is clear, the magnetic clutch is engaged
and there is no significant temperature difference between
compressor inlet and discharge lines; the system has
lost some refrigerant.
3. If the sight glass shows foam or bubbles, the system
could be low on charge. The system has to be recharged
with refrigerant.
MAGNETIC CLUTCH TEST
55200850303
1. Disconnect the connector (1-pin) to the magnetic clutch.

2. Connect battery (+) voltage directly to the connector for
the magnetic clutch.
3. If the magnetic clutch is normal, there will be click. If
the pulley and armature do not make contact (click),
there is a malfunction.
RECEIVER DRIER TEST
55200860115
Operate the unit and check the piping temperature by touching

the receiver drier outlet and inlet.
If there is a difference in the temperatures, the receiver drier
is restricted.
Replace the receiver drier.
COMPRESSOR DRIVE BELT ADJUSTMENT

55200100101
Refer to GROUP 11 - On-vehicle Service.
DUAL PRESSURE SWITCH CHECK

Suction hose
Dual pressure switch

LOW-PRESSURE
SIDE
ON
HIGH-PRESSURE
SIDE
OFF
196 20
196 - 250 2550 200 3140 200

kPa
55-9
55201040235
1. Remove the dual pressure switch connector and connect

the high/low pressure side terminals located on the
harness side as shown in the illustration.
2. Install a gauge manifold to the high-pressure side service
valve of the refrigerant line. (Refer to Performance Test.)
3. When the high/low pressure sides of the dual pressure
switch are at operation pressure (ON) and there is
continuity between the respective terminals, then the
condition is normal. If there is no continuity, replace the
switch.
55-10
CHARGING
High-pressure
valve
Low-pressure
valve
Gauge manifold
Charging hose
(yellow)
Adapter
valve
Charging hose
(blue)
Switch
R-12
connection
port
Vacuum
pump
Quick
joint (for adaptor
low
pressure)
Vacuum
pump
R-134a
connection
port
Power supply
plug
Switch
Low-pressure
service valve
A
Sleeve
55200120275
1. With the handles turned back all the way (valve closed),
install the adaptor valve to the low-pressure side of the
gauge manifold.
2. Connect the charging hose (blue) to the adaptor valve.
3. Connect the quick joint (for low-pressure) to the charging
hose (blue).
4. Connect the quick joint (for low-pressure) to the lowpressure service valve.
NOTE
The low-pressure service valve should be connected to
the suction hose.
Caution
(1) Use tools that are suited to R-134a.
(2) To install the quick joint, press section A firmly
against the service valve until a click is heard.
When connecting, run your hand along the hose
while pressing to ensure that there are no bends
in the hose.
5. Close the high and low-pressure valves of the gauge
manifold.
6. Install the vacuum pump adaptor to the vacuum pump.
7. Connect the vacuum pump plug to the vacuum pump
adaptor.
8. Connect the charging hose (yellow) to the R-134a
connection port of the vacuum pump adaptor.
9. Tighten the adaptor valve handle (valve open).
10. Open the low-pressure valve of the gauge manifold.
11. Turn the power switch of the vacuum pump to the ON
position.
NOTE
Even if the vacuum pump power switch is turned ON,
the vacuum pump will not operate because of the power
supply connection in step (7).
55-11
12. Turn the vacuum pump adaptor switch to the R-134a

side to start the vacuum pump.
Caution
Do not operate the compressor for evacuation.
13. Evacuate to a vacuum reading of 100 kPa or higher (takes
approx. 10 minutes).
14. Turn the vacuum pump adaptor switch OFF and allow
to stand it for 5 minutes.
Caution
Do not operate the compressor in the vacuum
condition; damage may occur.
15. Carry out a leak test. (Good if the negative pressure
does not drop.)
Low-pressure
service valve
Caution
If the negative pressure drops, increase the tightness
of the connections, and then repeat the evacuation
procedure from step (12).
Vacuum pump
Valve open
Valve close
Charging
valve
Adaptor valve
16. With the handle turned back all the way (valve open),
install the charging valve to the service can.
17. Turn the handle of the adaptor valve back all the way
(valve closed), remove it from the gauge manifold and
install the service can.
18. Tighten the handle of the charging valve (valve closed)
to puncture the service can.
Service can
Charging valve
19. Turn the handle of the charging valve back (valve open)
and tighten the handle of the adaptor valve (valve open) to
charge the system with refrigerant.
Caution
If the service can is inverted, liquid refrigerant may
be drawn into the compressor damaging it by liquid
compression. Keep the service can upright to ensure
that refrigerant is charged in gas state.
20. If the refrigerant is not drawn in, turn the handle of the
adaptor valve back all the way (valve closed).
21. Check for gas leaks using a leak detector.
If a gas leak is detected, re-tighten the connections, and
then repeat the charging procedure from evacuation in
step (12).
Service can
(Refrigerant container)
Low-pressure
service valve
Caution
The leak detector for R-134a should be used.
22. Start the engine.
23. Operate the A/C and set to the lowest temperature (MAX.
COOL).
55-12

24. Fix the engine speed at 1,500 r/min.
25. Tighten the handle of the adaptor valve (valve open)
to charge the required volume of refrigerant.
Caution
be drawn into the compressor damaging it by liquid
that refrigerant is charged in gas state.
26. After charging with refrigerant, turn the handle of the
adaptor valve back all the way (valve closed).
27. Tighten the charging valve handle (valve closed).
Remove the quick joint (for low-pressure) from the
low-pressure service valve.
NOTE
If the service can is not emptied completely, keep the
handles of the charging valve and adaptor valve closed
for the next charging.
Valve open
Charge valve
Valve close
Service can
(Refrigerant
container)
Adaptor valve
Charging hose (blue)
Quick joint (for low-pressure)
Quick joint
(for low-pressure)
Low-pressure
service valve
CORRECTING LOW REFRIGERANT LEVEL IN CASE THE

SERVICE CAN IS USED.
1. Install the charge valve with the handle turned all the
way back (valve open) to the service can.
2. Install the adaptor valve with the handle turned all the
way back (valve close) to the charging valve.
3. Connect the charging hose (blue) to the adaptor valve.
4. Connect the charging hose (blue) to the quick joint (for
low-pressure).
5. Tighten the handle of the charge valve (valve close),
and pierce the service can.
6. Turn the handle of the adaptor valve to bleed the air.
7. Install the quick joint (for low-pressure) to the low-pressure
service valve.
NOTE
the suction hose.
Charging valve
55-13

9. Operate the air conditioner and set at the lowest
temperature (MAX. COOL).
10. Fix the engine speed at 1,500 r/min.
11. Tighten the handle of the adaptor valve (valve open),
and replenish refrigerant while checking the quantity
through the sight glass.
Caution
be draw into the compressor damaging it by liquid
that refrigerant is changed in gas state.
Service can
(Refrigerant container)
12. After replenishing is completed, turn the handle of the

adaptor valve all the way back (valve close), and remove
the quick joint.
NOTE
When there is remainder of refrigerant in the service can,
keep it for next use with the charge value and the valve
of the adaptor valve being closed.
Low-pressure
service valve
DISCHARGING SYSTEM
1. Run the engine at an engine speed of 1,200 - 1,500 r/min
for approximately 5 minutes with the A/C operating to
return to the oil.
A
Sleeve
Charging hose (blue)
Quick joint
Low-pressure
service valve
NOTE
Returning the oil will be more effective if it is done while
driving.
2. Stop the engine.
3. Connect the charging hose (blue) to the adaptor valve
with its handle turned back all the way (valve closed).
4. Connect the quick joint to the charging hose (blue).
5. Install the quick joint to the low-pressure service valve.
NOTE
the suction hose.
Caution
To connect the quick joint, press section A firmly
When connecting, run your hand along the hose while
pressing to ensure that there are no bends in the
hose.
6. Place the adaptor valve inside the container and discharge
the refrigerant by opening the handle gradually so that
oil does not gush out.
Adaptor valve
Oil
NOTE
Any oil remaining in the container should be returned
to the A/C system.
55-14

REFILLING OF OIL IN THE A/C SYSTEM
Too little oil will provide inadequate compressor lubrication
and cause a compressor failure. Too much oil will increase
discharge air temperature.
When a compressor is installed at the factory, it contains
120 mL of refrigerant oil. While the A/C system is in operation,
the oil is carried through the entire system by the refrigerant.
Some of this oil will be trapped and retained in various parts
of the system.
When the following system components are changed, it is
necessary to add oil to the system to replace the oil being
removed with the component.
Compressor oil: DENSO OIL 8
Quantity
Condenser: 10 mL
Evaporator: 40 mL
Suction hose: 6.5 mL
PERFORMANCE TEST
Low-pressure valve
High-pressure valve
Gauge manifold
Charging
hose (red)
Charging
hose (blue)
A
Adaptor
valve (for low
pressure)
Sleeve
Adaptor valve
(for high pressure)
Lowpressure
service
valve
Highpressure
service
valve
55200140257
1. The vehicles to be tested should be in a place that is

not in direct sunlight.
2. Close the high and low-pressure valve of the gauge
manifold.
3. Connect the charging hose (blue) to the low-pressure
valve and connect the charging hose (red) to the
high-pressure valve of the gauge manifold.
4. Install the quick joint (for low-pressure) to the charging
hose (blue), and connect the quick joint (for high-pressure)
to the charging hose (red).
5. Connect the quick joint (for low-pressure) to the
low-pressure service valve and connect the quick joint
(for high-pressure) to the high-pressure service valve.
NOTE
The high-pressure service valve is on liquid pipe A and
the low-pressure service valve is on the suction hose.
Caution
To connect the quick joint, press section A firmly
When connecting, run your hand along the hose while
pressing to ensure that there are no bends in the
hose.
55-15
7. Set the controls to the A/C as follows:

A/C switch: A/C - ON position
Mode selection: Face position
Temperature control: Max. cooling position
Air selection: Recirculation position
Blower switch: HI (Fast) position
8. Adjust engine speed to 1,000 r/min with A/C clutch
engaged.
9. Engine should be warmed up with doors and windows
closed.
10. Insert a thermometer in the center A/C outlet and operate
the engine for 20 minutes.
11. Note the discharge air temperature.
Thermometer
NOTE
If the clutch cycles, take the reading before the clutch
disengages.
Performance Temperature Chart

Garage ambient temperature _C
20
25
35
40
Discharge air temperature _C
2.5 - 4.5
2.5 - 4.5
4.0 - 6.5
6.5 - 9.0
Compressor high-pressure kPa
765 - 960
765 - 960
1,325 - 1,420
1,570 - 1,765
Compressor low-pressure kPa
40 - 135
40 - 135
80 - 175
155 - 255
55-16
REFRIGERANT LEAK REPAIR
55200150045
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system. (See procedure.)
2. Charge the system with approximately one
pound of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
6. Replace receiver drier.
Caution
Replacement filter-drier units must be
sealed while in storage. The drier used in
these units will saturate water quickly upon
exposure to the atmosphere. When
installing a drier, have all tools and supplies
ready for quick reassembly to avoid keeping
the system open any longer than necessary.
7. Evacuate and charge system.
LOW CHARGE
If the system has not lost all of its refrigerant charge;
locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.
COMPRESSOR NOISE
55200870033
You must first know the conditions when the noise

occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or
any other special conditions.
Noises that develop during A/C operation can often
be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
caused by loose bolts, nuts, mounting brackets,
or a loose clutch assembly. Verify accessory drive
belt tension (power steering or alternator).
Improper accessory drive belt tension can cause
a misleading noise when the compressor is
engaged and little or no noise when the compressor
is disengaged.
Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the
compressor.
HANDLING TUBING AND FITTINGS

Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are
produced in the system when it is operating.
Extreme care must be exercised to make sure that
all connections are pressure tight. Dirt and moisture
can enter the system when it is opened for repair
or replacement of lines or components. The
following precautions must be observed. The
system must be completely discharged before
opening any fitting of connection in the refrigeration
system. Open fittings with caution even after the
system has been discharged. If any pressure is
noticed as a fitting is loosened, allow trapped
pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use
the correct line for the installation you are servicing.
A good rule for the flexible hose lines is keep the
radius of all bends at least 10 times the diameter
of the hose.
Sharper bends will reduce the flow of refrigerant.
The flexible hose lines should be routed so that
they are at least 80 mm from the exhaust manifold.
It is good practice to inspect all flexible hose lines
at least once a year to make sure they are in good
condition and properly routed.
Unified plumbing connections with O-rings, these
O-rings are not reusable.
ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure),
restrict air flow through condenser. Install
manifold gauge set to make sure discharge
pressure doesnt exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt.
Check to assure clutch coil is tight (no rotation
or wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge. (See Charging
System.)
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and
repeat Step 1.
POWER RELAY CHECK
55-17
55200880296
BLOWER RELAY
Battery voltage
Terminal No.
1
Blower relay
Power is not supplied

Power is supplied
A/C compressor relay
A/C COMPRESSOR RELAY

Battery voltage
Terminal No.
1
Power is not supplied

Power is supplied
FAN CONTROL RELAY

Refer to GROUP 14 - Radiator.
55-18
IDLE-UP OPERATION CHECK
55200160338
1. Before inspection and adjustment, set vehicle in the

following condition:
D Engine coolant temperature: 80 - 90_C
D Lights, electric cooling fan and accessories: Set to
OFF
D Transmission: Neutral (N or P for vehicles with A/T)
D Steering wheel: Straightforward
2. Check whether or not the idling speed is the standard
value.
Standard value: 650 50 r/min
3. When the A/C is running after turning the A/C switch
to ON, and the blower switch to the MH or HI position,
check to be sure that the idle speed is at the standard
value.
Standard value: 800 50 r/min
NOTE
There is no necessity to make an adjustment, because
the idling speed is automatically adjusted by the ISC
system. If, however, there occurs a deviation from the
standard value for some reason, check the ISC system.
(Refer to GROUP 13A - On-vehicle Service.)
AIR PURIFIER ASSEMBLY REPLACEMENT

Air purifier
assembly
Air purifier cover
55501100024
1. Remove the glove box.

2. Remove the air purifier cover and the air purifier assembly.
3. Install a new air purifier assembly and install the air purifier
cover.
4. Install the glove box.
Heater Control Assembly and
HEATER, AIR CONDITIONER AND VENTILATION - A/C switch
HEATER CONTROL ASSEMBLY AND A/C SWITCH
55-19
55200240162
REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
D Center Air Outlet Assembly, Instrument Under Cover
Removal and Installation (Refer to GROUP 52A Instrument Panel.)
Radio, Tape Player Removal and Installation (Refer

to GROUP 54.)
2
1
Removal steps
"BA 1. Air mix damper cable connection
"AA 2. Air outlet changeover damper cable
connection
3. Heater control assembly
INSTALLATION SERVICE POINTS

Air outlet
changeover
damper lever
DEF position
Air mix damper lever
MAX HOT
position
"AA AIR OUTLET CHANGEOVER DAMPER CABLE

CONNECTION
1. Set the air outlet changeover control knob on the heater
control assembly to the DEF position.
2. Set the air outlet changeover damper lever of the heater
unit to the DEF position (turn clockwise the damper lever
unit it stops), and then connect the cable to the lever.
"BA AIR MIX DAMPER CABLE CONNECTION

1. Set the temperature control knob on the heater control
assembly to the MAX HOT position.
2. Set the air mix damper lever of the heater unit to the
MAX HOT position (turn clockwise the damper lever until
it stops), and then connect the cable to the lever.
55-20
INSPECTION
55201250027
BLOWER SWITCH CONTINUITY CHECK

Switch position
Terminal No.
1
OFF
D (LO)
D (ML)
(MH)
D (HI)
Inside/outside air
changeover switch
INSIDE/OUTSIDE AIR CHANGEOVER SWITCH

CONTINUITY CHECK
Switch
position
Terminal No.
1
IND
RECIRC
ILL
FRESH
A/C SWITCH CONTINUITY CHECK

A/C switch
Switch position
Terminal No.
5
IND
OFF
ON
ILL
DISASSEMBLY AND REASSEMBLY
55-21
55100130084
5
1
4
3
AA"
Disassembly steps
1. Knob assembly
2. Bulb harness
3. Air outlet changeover damper cable
AA"
4. Air mix damper cable

5. Heater control panel
6. Blower switch assembly
DISASSEMBLY SERVICE POINT

Flat-tipped
screwdriver
Claw
part
AA" AIR OUTLET CHANGEOVER DAMPER

CABLE/AIR MIX DAMPER CABLE REMOVAL
Insert a flat-tipped screwdriver into the control base clip from
inner side, and then remove the cable by lifting the claw
part of the clip.
55-22
Heater Unit, Blower Unit,
HEATER, AIR CONDITIONER AND VENTILATION - Resister and Evaporator
HEATER UNIT, BLOWER UNIT, RESISTER AND EVAPORATOR
55201270054

Caution: SRS
When removing and installing the floor console assembly from vehicles equipped with SRS, do
not let it bump against the SRS-ECU or the components.
41 Nm
10
1
2
4
3
18 Nm
Piping connection
6
8
O-ring
A/C compressor oil:

DENSO OIL 8
Heater unit and blower unit removal steps
D Discharging
and
Charging
of
Refrigerant (Refer to P.55-10.)
D Discharging and Charging of Engine
Coolant (Refer to GROUP 14 On- vehicle Service.)
D Engine Cover Removal and Installation (Refer to GROUP 11 - Engine
Assembly.)
D Air Cleaner Assembly Removal and
Installation.
D Front Scuff Plate, Rear Scuff Plate
and Cowl Side Trim Removal and
Installation (Refer to GROUP 52A Trims.)
D Glove Box and Instrument Under
Cover Removal and Installation (Refer
to GROUP 52A - Instrument Panel.)
D Front Seat Assembly (Drivers side)
Removal and Installation (Refer to
GROUP 52A - Seat.)
D Shift Lever Assembly Removal and
Installation (Refer to GROUP 22 Transmission Control.) <M/T>
D Selector Lever Assembly Removal

and Installation (Refer to GROUP 23
- Transmission Control.) <A/T>
D Floor Carpet Removal and Installation.
D Door check and body connection
(driver side)
1. Air bag module
(Refer to GROUP 52B)
2. Steering wheel
3. Key inter lock cable <A/T>
4. Steering column shaft assembly
connection
5. Rear heater duct C <SPACE
WAGON>
6. Rear heater duct B
7. Heater hoses connection
8. Front pipe assembly connection
9. Instrument panel side cover
10. Instrument panel assembly
55-23
11
11
13
18
19
16
21
12
15
20
15
17
14
11
11.
12.
13.
14.
15.
16.
17.
21.
Instrument panel wiring harness

Blower unit
Intake duct
Glove box support bracket
Foot duct
Joint duct A
Joint duct B
Heater unit
Evaporator and Resister removal

steps
D Discharging and Charging of Refrigerant (Refer to P.55-10.)
D Engine Cover (Refer to GROUP 11
- Engine Assembly.)
D Air Cleaner Assembly
D Front Scuff Plate, Rear Scuff Plate
and Cowl Side Trim (Refer to
GROUP 52A - Trims.)
D Glove Box and Instrument Under
Cover (Refer to GROUP 52A Instrument Panel.)
8. Front pipe assembly connection
19. Expansion valve
14. Glove box support bracket
16. Joint duct A
17. Joint duct B
18. Resistor
15. Foot duct (passengers side)
20. Evaporator
55-24
INSPECTION
RESISTOR CHECK
55100510031
Use a circuit tester to measure the resistance between the

terminals as indicated below. Check that the measured value
is at the standard value.
Standard value:
Measurement terminal
Standard value W
Between terminals 3 and 2 (LO)
2.30
Between terminals 3 and 4 (ML)
1.10
Between terminals 3 and 1 (MH)
0.40
55100540016
Disassembly steps
1. Heater core
2. Expansion valve
3. Evaporator
HEATER, AIR CONDITIONER AND VENTILATION - Air Thermo Sensor
AIR THERMO SENSOR
55-25
55201350017
Removal steps
1. Air thermo sensor clip
2. Air thermo sensor
INSPECTION
Resistance kW
8
AIE THERMO SENSOR CHECK

Measure the resistance between terminals under two or more
temperature conditions. The resistance should be close to
the values shown in the graph.
6
4
2
0
- 10
55201360010
10
20
Temperature
30
40_C
55-26
HEATER, AIR CONDITIONER

AND VENTILATION
Blower Motor Assembly, Automatic compressor - ECU

and Inside/Outside Air Changeover Damper Motor
BLOWER MOTOR ASSEMBLY, AUTOMATIC COMPRESSOR-ECU

AND INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR 55100500045
3
1. Blower motor assembly

2. Automatic compressor-ECU
Inside/outside air changeover

damper motor removal steps
3. Instrument panel
(Refer to GROUP 52A)
4. Inside/outside air changeover
damper motor
INSPECTION
55100510048
BLOWER MOTOR CHECK

When battery voltage is applied between the terminals, check
that the motor operates. Also, check that there is no abnormal
noise.
INSIDE/OUTSIDE CHANGEOVER DAMPER MOTOR

CHECK
Battery connection terminal
1
Lever operation
7
Moves to the outside air
position
Moves to the inside air
position
Inside/outside air changeover damper motor
Caution
Cut off the battery voltage when the damper is in the
inside air position or outside air position.
HEATER, AIR CONDITIONER AND VENTILATION - Compressor and Tension Pulley
COMPRESSOR AND TENSION PULLEY
55-27
55200410471

Pre-removal Operation
D Discharging of Refrigerant (Refer to P.55-13.)
Piping connection
Post-installation Operation
D Charging of Refrigerant (Refer to P.55-10.)
D Drive Belt Tension Adjustment
(Refer to GROUP 11 - On-vehicle Service.)
< 4G9-GDI>
2
26 Nm
3
O-ring
5
Compressor oil:
DENSO OIL 8
< 4G6-GDI>
26 Nm
4
1
AA"
Removal steps
D Under cover
D Condenser fan (Refer to P.55-33.)
1. Drive belt
2. Tension pulley
AB"
3. Suction hose and discharge hose

connection
AC" "AA 4. Compressor
5. Compressor bracket
55-28
REMOVAL SERVICE POINTS

B
A
AA" DRIVE BELT REMOVAL

1. Loosen the nut A for holding.
2. Loosen the bolt B for adjustment.
3. Remove the drive belt.
AB" SUCTION HOSE, DISCHARGE HOSE
DISCONNECTION
Plug the disconnected hose and the compressor nipple not
to let foreign matter get into them.
Caution
Seal the hoses completely, otherwise the compressor
oil and receiver will absorb water vapour easily.
AC" COMPRESSOR REMOVAL
When doing this work, be careful not to spill the compressor
oil.
INSTALLATION SERVICE POINT

"AA COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the amount of
oil according to the procedures described below, and then
install the compressor.
1. Measure the amount (X mL) of oil within the removed
compressor.
2. Drain (from the new compressor) the amount of oil
calculated according to the following formula, and then
install the new compressor.
New compressor oil amount
80 mL - X mL = Y mL
NOTE
(1) Y mL indicates the amount of oil in the refrigerant
line, the condenser, the evaporator etc.
(2) When replacing the following parts at the same time
as the compressor, subtract the rated oil amount of
the each part from Y mL and discharge from the
new compressor.
Quantity
Evaporator: 40 mL
Condenser: 10 mL
55-29
INSPECTION
55200850310
COMPRESSOR MAGNETIC CLUTCH OPERATION

INSPECTION
Connect the battery (+) terminal to the compressor side
terminal, and earth the battery ( - ) terminal to the body of
the compressor. The condition is normal if the sound of the
magnetic clutch (click) can be heard.
MAGNETIC CLUTCH
55200460346
6
5
4
3
1
2
14 Nm
Magnetic clutch disassembly steps

"BA D Air gap adjustment
AA"
1. Armature plate
2. Shims
"AA 3. Snap ring
4. Rotor
5. Snap ring
6. Clutch coil
DISASSEMBLY SERVICE POINT

MB991386
MB991367
AA" ARMATURE PLATE REMOVAL
55-30
Snap ring

Rotor
Clutch coil
REASSEMBLY SERVICE POINTS

"AA SNAP RING INSTALLATION
Install the snap ring so that the tapered surface is at the
outer side.
Tapered part
"BA AIR GAP ADJUSTMENT

Check whether or not the air gap of the clutch is within the
standard value.
Standard value: 0.25 - 0.55 mm
NOTE
If there is a deviation of the air gap from the standard value,
make the necessary adjustment by adjusting the number of
shims.
Condenser and Condenser
HEATER, AIR CONDITIONER AND VENTILATION - Fan Motor
CONDENSER AND CONDENSER FAN MOTOR
55-31
55200670381

1
4
Piping connection
3 2
8
14
12
7
8
O-ring
11 13
Compressor oil:
DENSO OIL 8
6
12 Nm
10
Condenser fan motor removal

steps
1. Condenser fan motor and shroud
assembly
2. Condenser fan motor cover
3. Condenser fan motor assembly
4. Condenser fan
5. Condenser fan shroud
Condenser removal steps

D Discharging and charging of
refrigerant (Refer to P.55-10.)
D Discharging and charging of
engine coolant (Refer to GROUP 14
- On- vehicle service.)
D Air cleaner assembly
D Radiator grille (Refer to GROUP 51
- Radiator grille.) <SPACE RUNNER>
6. Reserve tank
7. Air intake duct
AA"
8. Discharge hose and liquid pipe A
connection
9. Condenser upper bracket
D Under Cover Removal and Installation
10. Air guide panel
11. Radiator upper mounting bolts
12. Condenser side cover
13. Condenser lower bracket
AB" "AA 14. Condenser assembly
55-32
Condenser and Condenser
HEATER, AIR CONDITIONER AND VENTILATION - Fan Motor
REMOVAL SERVICE POINTS

AA" DISCHARGE HOSE AND LIQUID PIPE A
DISCONNECTION
Plug the disconnected pipe, hose and the condenser nipple
not to let foreign matter get into them.
Caution
AB" CONDENSER ASSEMBLY REMOVAL

1. Remove the installation bolts from headlamp support
member side.
2. Disengage the lower part of the radiator, and then move
the radiator slightly toward the engine.
3. Raise the condenser assembly to remove it from the
engine compartment.

"AA CONDENSER ASSEMBLY INSTALLATION
When replacing the condenser, refill it with a specified amount
of compressor oil and install it. (to the vehicle).
Quantity: 10 mL
INSPECTION
55200680209
CONDENSER FAN MOTOR CHECK

Check to be sure that the condenser fan motor operates.
Terminals connected to battery
1
2
Condenser fan condition

Operates
HEATER, AIR CONDITIONER AND VENTILATION - Refrigerant Line
REFRIGERANT LINE
55-33
55200640375

<L.H. DRIVE VEHICLES>
D Discharging and Charging of Refrigerant
(Refer to P.55-10.)
D Engine Cover Removal and Installation
(Refer to GROUP 11 - Engine Assembly.)
D
D
Air Cleaner Assembly Removal and Installation.

Canister Removal and Installation
(Refer to GROUP 17.)
1, 3
Piping connection
1, 2, 3, 5
O-ring
O-ring
4
1
AA" "AA
AA"
AA"
Removal steps
1. Suction hose
2. Discharge hose
3. Liquid pipe A
AA"
4. Clamp
5. Front pipe assembly
55-34
<R.H. DRIVE VEHICLES>

D Discharging and Charging of Refrigerant
(Refer to P.55-10.)
D Engine Cover Removal and Installation
(Refer to GROUP 11 - Engine Assembly.)
D
D
Air Cleaner Assembly Removal and Installation.

Canister Removal and Installation
(Refer to GROUP 17.)
Piping connection
1, 3
1, 2, 3, 5
O-ring
O-ring
4
1
AA" "AA
AA"
AA"
Removal steps
1. Suction hose
2. Discharge hose
3. Liquid pipe A
AA"
4. Clamp
5. Front pipe assembly
6. Clamp
55-35
REMOVAL SERVICE POINT

AA" HOSE/PIPE DISCONNECTION
Plug the disconnected hose, the receiver, the evaporator and
the compressor nipple not to let foreign matter get into them.
Caution

"AA SUCTION HOSE INSTALLATION
When replacing the suction hose, refill them with a specified
amount of compressor oil, and then install them.
Quantity:
55-36
HEATER, AIR CONDITIONER AND VENTILATION - Ventilators
VENTILATORS
55300160287

Caution: SRS
When removing and installing the floor console assembly from vehicles equipped with SRS, do
not let it bump against the SRS-ECU or the components.
2
3
<SPACE RUNNER>
4
5
Rear heater duct B removal steps

D Front scuff plate, cowl side trim and
center console assembly (Refer to
GROUP 52A - Instrument Panel.)
D Floor carpet
Defroster nozzle and distribution
duct removal steps
D Instrument panel
(Refer to GROUP 52A.)
2. Side defroster duct
3. Defroster nozzle assembly
4. Distribution duct
Foot distribution duct and rear

heater duct A removal steps
D Instrument panel
D Blower unit, joint duct and glove box
support bracket (Refer to P.55-22.)
5. Foot distribution duct
6. Rear heater duct A
NOTE
For the center air outlet assembly and the side air outlet
assembly, refer to GROUP 52A - Instrument panel.
<SPACE WAGON>
55-37
6
7
3
1
Rear heater duct B and rear heater

duct C removal steps
D Front scuff plate, rear scuff plate, cowl
side trim and center console assembly
(Refer to GROUP 52A - Instrument
Panel.)
D Front seats and second seats (Refer
to GROUP 52A - Seats.)
D Seat adjuster side cover and seat
adjuster end cover (Refer to GROUP
52A - Seats.)
D Floor carpet
1. Rear heater nozzle garnish
2. Rear heater duct C
Defroster nozzle and distribution
duct removal steps
D Instrument panel
4. Side defroster duct
5. Defroster nozzle assembly
6. Distribution duct
Foot distribution duct and rear

heater duct A removal steps
D Instrument panel
D Blower unit, joint duct and glove box
support bracket (Refer to P.55-22.)
7. Foot distribution duct
8. Rear heater duct A
NOTE
For the center air outlet assembly and the side air outlet
assembly, refer to GROUP 52A - Instrument panel.
55-38
<SPACE RUNNER>
Rear ventilation duct
<SPACE WAGON>
Rear ventilation duct
NOTE
For the front deck garnish, refer to GROUP 51 - Windshield wiper and washer.
RJST809004 - 1164

Heater, Air Conditioner and Ventilation

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55-1

Sight Glass Refrigerant Level Test . . . . . . . . . . 8

Magnetic Clutch Test . . . . . . . . . . . . . . . . . . . . . . 8

CONTINUED ON NEXT PAGE

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

HEATER CONTROL ASSEMBLY AND A/C

AIR THERMO SENSOR . . . . . . . . . . . . . . . . 25

HEATER UNIT*, BLOWER UNIT*,

HEATER, AIR CONDITIONER AND VENTILATION - General Information

refrigerant system has been adopted as a response

Two-way-flow full-air-mix system

Heater control assembly

Scroll type <CSC08>

Dual pressure switch

ON OFF: 2,940, OFF ON: 2,350

ON OFF: 196, OFF ON: 221

Refrigerant and quantity g

R-134a (HFC-134a), Approx. 500 - 600

In most instances, moderate heat is required to

HEATER, AIR CONDITIONER AND VENTILATION

Service Specifications/Lubricants/Special Tools

Idle speed r/min

Idle up speed r/min

Resistor (for blower motor) W

LO: 2.30, ML:1.10, MH: 0.40

Air gap (Magnetic clutch)

Each connection of refrigerant line

Compressor refrigerant unit lubricant mL

Removal and installation of armature mounting

HEATER, AIR CONDITIONER AND VENTILATION - Troubleshooting

When the ignition

Replace the fuse

Harness or connector is defective

Repair the harness or connector

A/C compressor relay is defective

Replace the A/C compressor

A/C compressor magnetic clutch is defective

Replace the armature plate, rotor

Refrigerant leak or overfilling of refrigerant

Replenish the refrigerant, repair

Dual pressure switch is defective

Replace the dual pressure switch

A/C switch is defective

Replace the blower switch assembly

Blower switch is defective

Replace the blower switch assembly

Automatic compressor-ECU is defective

Replace the automatic compressor-ECU

Replace the engine-ECU

When the A/C is

Replenish the refrigerant and

Dual pressure switch is defective

Replace the dual pressure switch

Automatic compressor-ECU is defective

Replace the automatic compressor-ECU

Replace the engine-ECU

Blower fan and

Replace the fuse

Harness or connector is defective

Repair the harness or connector

Blower relay is defective

Replace the blower relay

Blower fan and motor are defective

HEATER UNIT, BLOWER UNIT,